Land vehicles incorporating monocoques and modular mold systems for making the same

ABSTRACT

Land vehicles, modular systems for forming monocoques of land vehicles, and methods of forming monocoques of land vehicles using modular systems are disclosed herein. In certain embodiments, the land vehicles are provided as delivery vehicles and/or utility vehicles. A land vehicle includes a monocoque supporting a plurality of wheels to permit movement of the vehicle relative to an underlying surface in use of the land vehicle.

CROSS-REFERENCE TO RELATED APPLICATION(S)

The present application claims priority to, and the benefit of, U.S.Provisional App. Ser. No. 62/957,577 entitled “SYSTEMS AND METHODS FORMANUFACTURING LAND VEHICLES,” which was filed on Jan. 6, 2020. Thecontents of that application are incorporated by reference herein intheir entirety.

TECHNICAL FIELD

The present disclosure generally relates to land vehicles and methods ofmaking land vehicles, and, more particularly, to utility and delivervehicles and methods of making utility and delivery vehicles.

BACKGROUND

Current systems and methods for manufacturing utility and deliveryvehicles suffer from a variety of drawbacks and limitations. For thosereasons, among others, there remains a need for further improvements inthis technological field.

SUMMARY

The present disclosure may comprise one or more of the followingfeatures and combinations thereof.

According to one aspect of the present disclosure, a land vehicle mayinclude a monocoque supporting a plurality of wheels to permit movementof the vehicle relative to an underlying surface in use of the landvehicle. The monocoque may be a single-piece, monolithic structureunsupported by an internal chassis. The monocoque may include a frontcage defining an operator cabin and a rear floor positioned rearward ofthe front cage. The monocoque may have a composite construction suchthat each of the front cage and the rear floor are formed from one ormore composite materials.

In some embodiments, the monocoque may not include metallic material,the monocoque may include a core and a shell that at least partiallysurrounds the core, the core may be formed from one or more lightweight,low-density materials, and the shell may be formed from resin andfiberglass. The core may include balsa wood. The core may include one ormore of the following: fiberglass, Kevlar, carbon fiber, or plastic. Themonocoque may include a laminate layer that at least partially coversthe shell.

In some embodiments, the monocoque may include an intermediate sectiondisposed between the front cage and the rear floor, the vehicle mayinclude a stowage compartment at least partially defined by theintermediate section and the rear floor that has a plurality ofsidewalls and a ceiling, each of the intermediate section, the pluralityof sidewalls, and the ceiling may be formed from one or more compositematerials, and each of the intermediate section, the plurality ofsidewalls, and the ceiling may not include metallic material. Thestowage compartment may have a volume of 650 cubic feet, 1000 cubicfeet, or 1200 cubic feet. Additionally, in some embodiments, the vehiclemay have a weight limit of between 10,001 pounds and 14,000 pounds.Further, in some embodiments still, the land vehicle may include arefrigeration unit at least partially housed by the stowage compartmentthat is configured to cool the stowage compartment.

In some embodiments, the vehicle may not include an internal combustionengine. A height of the rear floor above the underlying surface may bebetween 22 inches and 28 inches.

According to another aspect of the present disclosure, a modular systemfor forming a monocoque of a land vehicle may include a front cage moldunit, a rear floor mold unit, and a plurality of intermediate moldunits. The front cage mold unit may include a front cage mold cavitythat has a size and a shape corresponding to a front cage of themonocoque defining an operator cabin. The front cage mold unit may havean opening at a rear end thereof to establish a fluidic coupling betweenthe front cage mold cavity and another component of the system. The rearfloor mold unit may include a rear floor mold cavity that has a size anda shape corresponding to a rear floor of the monocoque positionedrearward of the front cage. The rear floor mold unit may have an openingat a front end thereof to establish a fluidic coupling between the rearfloor mold cavity and another component of the system. Each of theplurality of intermediate mold units may be sized for positioningbetween the front cage mold unit and the rear floor mold unit. Each ofthe plurality of intermediate mold units may include an intermediatemold cavity that has a size and a shape corresponding to an intermediatesection of the monocoque positioned between the front cage and the rearfloor. Each of the plurality of intermediate mold units may have a frontopening at a front end thereof to establish a fluidic coupling betweenthe intermediate mold cavity and the front cage mold cavity and a rearopening at a rear end thereof to establish a fluidic coupling betweenthe intermediate mold cavity and the rear floor mold cavity.

In some embodiments, the front end of each of the plurality ofintermediate mold units may be configured for direct connection to therear end of the front cage mold unit. The rear end of each of theplurality of intermediate mold units may be configured for directconnection to the front end of the rear floor mold unit. When any one ofthe intermediate mold units is directly connected with the front cagemold unit and the rear floor mold unit, the front cage mold cavity, theintermediate mold cavity, and the rear floor mold cavity may befluidically coupled to one another in a contiguous arrangement toestablish a continuous monocoque mold cavity into which one or morecomposite materials may be introduced to form the monocoque as asingle-piece, monolithic structure.

In some embodiments, the rear end of the front cage mold unit may beconfigured for direct connection to the front end of the rear floor moldunit. When the front cage mold unit is directly connected to the rearfloor mold unit, the front cage mold unit and the rear floor mold unitmay be fluidically coupled to one another in a contiguous arrangement toestablish a continuous monocoque mold cavity into which one or morecomposite materials may be introduced to form the monocoque as asingle-piece, monolithic structure.

In some embodiments, the plurality of intermediate mold units mayinclude a first intermediate mold unit having a first length, a secondintermediate mold unit having a second length greater than the firstlength, and a third intermediate mold unit having a third length greaterthan the second length. The first intermediate mold unit may be sized toform an intermediate section of the monocoque included in a vehiclehaving a storage volume of 650 cubic feet, the second intermediate moldunit may be sized to form an intermediate section of the monocoqueincluded in a vehicle having a storage volume of 1000 cubic feet, andthe third intermediate mold unit may be sized to form an intermediatesection of the monocoque included in a vehicle having a storage volumeof 1200 cubic feet.

According to yet another aspect of the present disclosure, a landvehicle may include a monocoque supporting a plurality of wheels topermit movement of the vehicle relative to an underlying surface in useof the land vehicle. The monocoque may be a single-piece, monolithicstructure unsupported by an internal chassis. The monocoque may includea front cage defining an operator cabin, a rear floor positionedrearward of the front cage, and an intermediate section disposed betweenthe front cage and the rear floor. The monocoque may include a coreformed from balsa wood or plastic and a shell formed from resin andfiberglass that at least partially surrounds the core. The monocoque maybe formed by a modular system including a front cage mold unit, a rearfloor mold unit, and an intermediate mold unit. The front cage mold unitmay include a front cage mold cavity that has a size and a shapecorresponding to the front cage of the monocoque. The front cage moldunit may have an opening at a rear end thereof to establish a fluidiccoupling between the front cage mold cavity and another component of thesystem. The rear floor mold unit may include a rear floor mold cavitythat has a size and a shape corresponding to the rear floor of themonocoque. The rear floor mold unit may have an opening at a front endthereof to establish a fluidic coupling between the rear floor moldcavity and another component of the system. The intermediate mold unitmay be sized for positioning between the front cage mold unit and therear floor mold unit. The intermediate mold unit may include anintermediate mold cavity that has a size and a shape corresponding tothe intermediate section of the monocoque. The intermediate mold unitmay have a front opening at a front end thereof to establish a fluidiccoupling between the intermediate mold cavity and the front cage moldcavity and a rear opening at a rear end thereof to establish a fluidiccoupling between the intermediate mold cavity and the rear floor moldcavity.

According to yet another aspect of the present disclosure still, amethod of forming a monocoque of a land vehicle using a modular systemmay include the following: selecting a monocoque configuration of theland vehicle; selecting a first mold unit of the modular system basedupon the selected monocoque configuration; coupling the selected firstmold unit to a front cage mold unit of the modular system such that afront cage mold cavity of the front cage mold unit is fluidly coupled toa mold cavity of the selected first mold unit to at least partiallyestablish a continuous monocoque mold cavity; introducing one or morecomposite materials into the continuous monocoque mold cavity; andcuring the one or more composite materials in the continuous monocoquemold cavity to form the monocoque.

In some embodiments, introducing the one or more composite materialsinto the continuous monocoque mold cavity may include introducing theone or more composite materials into the continuous monocoque moldcavity without introducing metallic material into the continuousmonocoque mold cavity. Additionally, in some embodiments, the front cagemold unit of the modular system may correspond to a front cage of themonocoque that defines an operator cabin of the vehicle, and theselected first mold unit of the modular system may correspond to a rearfloor of the monocoque that is positioned rearward of the front cage.

In some embodiments, introducing the one or more composite materialsinto the continuous monocoque mold cavity may include placing a firstmaterial in the continuous monocoque mold cavity and placing a secondmaterial different from the first material in the continuous monocoquemold cavity. The first material may include balsa wood or plastic, andthe second material may include fiberglass and resin. Curing the one ormore composite materials in the continuous monocoque mold cavity mayinclude forming a core including the first material and forming a shellincluding the second material that at least partially surrounds thecore.

In some embodiments, the front cage mold unit of the modular system maycorrespond to a front cage of the monocoque that defines an operatorcabin of the vehicle, and the selected first mold unit of the modularsystem may correspond to an intermediate section of the monocoque thatis positioned rearward of the front cage. The method may further includeselecting a second mold unit of the modular system corresponding to arear floor of the monocoque that is positioned rearward of the frontcage and the intermediate section based upon the selected monocoqueconfiguration, and coupling the selected first mold unit to the selectedsecond mold unit such that the front cage mold cavity of the front cagemold unit, the cavity of the selected first mold unit, and a mold cavityof the selected second mold unit are fluidly coupled to one another toestablish the continuous monocoque mold cavity. Selecting the first moldunit of the modular system may include selecting one of a smallintermediate section mold unit of the modular system having a firstlength, a medium intermediate section mold unit of the modular systemhaving a second length greater than the first length, and a largeintermediate section mold unit of the modular system having a thirdlength greater than the second length.

According to a further aspect of the present disclosure, a method offorming multiple monocoques of land vehicles using at least one modularsystem may include the following: selecting a first monocoqueconfiguration for a first monocoque of a first land vehicle; selecting afirst mold unit of at least one modular system based upon the selectedfirst monocoque configuration; coupling the selected first mold unit toa front cage mold unit of the at least one modular system such that afront cage mold cavity of the front cage mold unit is fluidly coupled toa mold cavity of the selected first mold unit to at least partiallyestablish a first continuous monocoque mold cavity; introducing one ormore composite materials into the first continuous monocoque moldcavity; curing the one or more composite materials in the firstcontinuous monocoque mold cavity to form the first monocoque; selectinga second monocoque configuration for a second monocoque of a second landvehicle different from the first land vehicle; selecting a first moldunit of at least one modular system based upon the selected secondmonocoque configuration that is different from the selected first moldunit of the at least one modular system; coupling the selected firstmold unit of the at least one modular system to a front cage mold unitof the at least one modular system such that a front cage mold cavity ofthe front cage mold unit of the at least one modular system is fluidlycoupled to a mold cavity of the selected first mold unit of the at leastone modular system to at least partially establish a second continuousmonocoque mold cavity; introducing one or more composite materials intothe second continuous monocoque mold cavity; and curing the one or morecomposite materials in the second continuous monocoque mold cavity toform the second monocoque.

In some embodiments, introducing the one or more composite materialsinto the first continuous monocoque mold cavity may include introducingthe one or more composite materials into the first continuous monocoquemold cavity without introducing metallic material into the firstcontinuous monocoque mold cavity, and introducing the one or morecomposite materials into the second continuous monocoque mold cavity mayinclude introducing the one or more composite materials into the secondcontinuous monocoque mold cavity without introducing metallic materialinto the second continuous monocoque mold cavity.

In some embodiments, introducing the one or more composite materialsinto the first continuous monocoque mold cavity may include placing afirst material in the first continuous monocoque mold cavity and placinga second material different from the first material in the firstcontinuous monocoque mold cavity, and introducing the one or morecomposite materials into the second continuous monocoque mold cavity mayinclude placing the first material in the second continuous monocoquemold cavity and placing the second material in the second continuousmonocoque mold cavity. The first material may include balsa wood orplastic and the second material may include fiberglass and resin. Curingthe one or more composite materials in the first continuous monocoquemold cavity may include forming a core of the first monocoque includingthe first material and forming a shell of the first monocoque includingthe second material that at least partially surrounds the core of thefirst monocoque, and curing the one or more composite materials in thesecond continuous monocoque mold cavity may include forming a core ofthe second monocoque including the first material and forming a shell ofthe second monocoque including the second material that at leastpartially surrounds the core of the second monocoque.

In some embodiments, the front cage mold unit of the at least onemodular system may correspond to a front cage of the first monocoquethat defines an operator cabin of the first land vehicle, the selectedfirst mold unit of the at least one modular system may correspond to arear floor of the first monocoque that is positioned rearward of thefront cage of the first monocoque, the front cage mold unit of the atleast one modular system may correspond to a front cage of the secondmonocoque that defines an operator cabin of the second land vehicle, andthe selected first mold unit of the at least one modular system maycorrespond to an intermediate section of the second monocoque that ispositioned rearward of the front cage of the second monocoque.

In some embodiments, the method may further include selecting a secondmold unit of the at least one modular system corresponding to a rearfloor of the second monocoque that is positioned rearward of the frontcage and the intermediate section of the second monocoque based upon theselected second monocoque configuration, and coupling the selected firstmold unit of the at least one modular system to the selected second moldunit of the at least one modular system such that the front cage moldcavity of the front cage mold unit of the at least one modular system,the cavity of the selected first mold unit of the at least one modularsystem, and a mold cavity of the selected second mold unit of the atleast one modular system are fluidly coupled to one another to establishthe second continuous monocoque mold cavity. Selecting the first moldunit of the at least one modular system may include selecting one of asmall intermediate section mold unit of the at least one modular systemhaving a first length, a medium intermediate section mold unit of the atleast one modular system having a second length greater than the firstlength, and a large intermediate section mold unit of the at least onemodular system having a third length greater than the second length.

In some embodiments, the front cage mold unit of the at least onemodular system may correspond to a front cage of the first monocoquethat defines an operator cabin of the first land vehicle, the selectedfirst mold unit of the at least one modular system may have a firstlength and correspond to an intermediate section of the first monocoquethat is positioned rearward of the front cage of the first monocoque,the front cage mold unit of the at least one modular system maycorrespond to a front cage of the second monocoque that defines anoperator cabin of the second land vehicle, and the selected first moldunit of the at least one modular system may have a second lengthdifferent from the first length and correspond to an intermediatesection of the second monocoque that is positioned rearward of the frontcage of the second monocoque. The method may further include thefollowing: selecting a second mold unit of the at least one modularsystem corresponding to a rear floor of the first monocoque that ispositioned rearward of the front cage and the intermediate section ofthe first monocoque based upon the selected first monocoqueconfiguration; coupling the selected first mold unit of the at least onemodular system to the selected second mold unit of the at least onemodular system such that the front cage mold cavity of the front cagemold unit of the at least one modular system, the cavity of the selectedfirst mold unit of the at least one modular system, and a mold cavity ofthe selected second mold unit of the at least one modular system arefluidly coupled to one another to establish the first continuousmonocoque mold cavity; selecting a second mold unit of the at least onemodular system corresponding to a rear floor of the second monocoquethat is positioned rearward of the front cage and the intermediatesection of the second monocoque based upon the selected second monocoqueconfiguration; and coupling the selected first mold unit of the at leastone modular system to the selected second mold unit of the at least onemodular system such that the front cage mold cavity of the front cagemold unit of the at least one modular system, the cavity of the selectedfirst mold unit of the at least one modular system, and a mold cavity ofthe selected second mold unit of the at least one modular system arefluidly coupled to one another to establish the second continuousmonocoque mold cavity.

According to a further aspect of the present disclosure still, a methodof forming multiple monocoques of land vehicles using at least onemodular system includes the following: selecting a first monocoqueconfiguration for a first monocoque of a first land vehicle; selecting afirst mold unit of at least one modular system based upon the selectedfirst monocoque configuration; coupling the selected first mold unit toa front cage mold unit of the at least one modular system such that afront cage mold cavity of the front cage mold unit is fluidly coupled toa mold cavity of the selected first mold unit to at least partiallyestablish a first continuous monocoque mold cavity; introducing one ormore composite materials into the first continuous monocoque moldcavity; curing the one or more composite materials in the firstcontinuous monocoque mold cavity to form the first monocoque; selectinga second monocoque configuration for a second monocoque of a second landvehicle different from the first land vehicle; selecting a first moldunit of the at least one modular system based upon the selected secondmonocoque configuration that is different from the selected first moldunit of the at least one modular system; coupling the selected firstmold unit of the at least one modular system to a front cage mold unitof the at least one modular system such that a front cage mold cavity ofthe front cage mold unit of the at least one modular system is fluidlycoupled to a mold cavity of the selected first mold unit of the at leastone modular system to at least partially establish a second continuousmonocoque mold cavity; introducing one or more composite materials intothe second continuous monocoque mold cavity; curing the one or morecomposite materials in the second continuous monocoque mold cavity toform the second monocoque; selecting a third monocoque configuration fora third monocoque of a third land vehicle different from the first landvehicle and the second land vehicle; selecting a first mold unit of theat least one modular system based upon the selected third monocoqueconfiguration that is different from the selected first mold unit of theat least one modular system and the selected first mold unit of the atleast one modular system; coupling the selected first mold unit of theat least one modular system to a front cage mold unit of the at leastone modular system such that a front cage mold cavity of the front cagemold unit of the at least one modular system is fluidly coupled to amold cavity of the selected first mold unit of the at least one modularsystem to at least partially establish a third continuous monocoque moldcavity; introducing one or more composite materials into the thirdcontinuous monocoque mold cavity; and curing the one or more compositematerials in the third continuous monocoque mold cavity to form thethird monocoque.

Further still, according to another aspect of the present disclosure, aland vehicle may include a monocoque supporting a plurality of wheels topermit movement of the vehicle relative to an underlying surface in useof the land vehicle. The monocoque may be a single-piece, monolithicstructure unsupported by an internal chassis. The monocoque may includea front cage defining an operator cabin and a rear floor positionedrearward of the front cage. The monocoque may have a compositeconstruction such that each of the front cage and the rear floor areformed from one or more composite materials. The monocoque may notinclude metallic material

In some embodiments, the monocoque may include a core and a shell thatat least partially surrounds the core, the core may be formed from balsawood and plastic, and the shell may be formed from resin and fiberglass.The monocoque may include an intermediate section disposed between thefront cage and the rear floor, the vehicle may include a stowagecompartment at least partially defined by the intermediate section andthe rear floor that has a plurality of sidewalls and a ceiling, each ofthe intermediate section, the plurality of sidewalls, and the ceilingmay be formed from one or more composite materials, and each of theintermediate section, the plurality of sidewalls, and the ceiling maynot include metallic material. The vehicle may not include an internalcombustion engine. A height of the rear floor above the underlyingsurface may be between 22 inches and 28 inches

These and other features of the present disclosure will become moreapparent from the following description of the illustrative embodiments.

BRIEF DESCRIPTION OF THE FIGURES

The invention described herein is illustrated by way of example and notby way of limitation in the accompanying figures. For simplicity andclarity of illustration, elements illustrated in the figures are notnecessarily drawn to scale. For example, the dimensions of some elementsmay be exaggerated relative to other elements for clarity. Further,where considered appropriate, reference labels have been repeated amongthe figures to indicate corresponding or analogous elements.

FIG. 1 depicts side elevation views of a number of electric vehiclesthat may be included in an electric vehicle line according to certainembodiments of the disclosure;

FIG. 2 is a perspective view of a monocoque or unibody that may beincorporated into any electric vehicle of the disclosure;

FIG. 3 is a partially exploded assembly view of an electric vehicleaccording to at least one embodiment of the disclosure;

FIG. 4 is a partial schematic rear end view of a conventional deliveryvehicle;

FIG. 5 is a partial schematic rear end view of a delivery vehicleaccording to at least one embodiment of the disclosure;

FIG. 6 is a table illustrating United States standard vehicle classes bygross vehicular weight rating (GVWR);

FIG. 7 is a partial schematic depiction of a composite structure thatmay be used to form a monocoque or unibody of any electric vehicle ofthe disclosure;

FIG. 8 is a diagrammatic depiction of at least one modular mold systemaccording to certain embodiments of the disclosure;

FIG. 9 is a perspective view of a monocoque system formed from a numberof mold units included in the at least one modular mold system of FIG.8;

FIG. 10 is a simplified flowchart of a method of forming a monocoque ofan electric vehicle using one modular mold system according to oneembodiment of the disclosure;

FIG. 11 is a simplified flowchart of one portion of another method offorming a monocoque of an electric vehicle using one modular mold systemaccording to another embodiment of the disclosure;

FIG. 12 is a diagrammatic view of another portion of the method of FIG.11; and

FIG. 13 is a simplified flowchart of a method of forming multiplemonocoques of electric vehicles using at least one modular mold systemaccording to yet another embodiment of the disclosure.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

While the concepts of the present disclosure are susceptible to variousmodifications and alternative forms, specific embodiments thereof havebeen shown by way of example in the drawings and will be describedherein in detail. It should be understood, however, that there is nointent to limit the concepts of the present disclosure to the particularforms disclosed, but on the contrary, the intention is to cover allmodifications, equivalents, and alternatives consistent with the presentdisclosure and the appended claims.

References in the specification to “one embodiment,” “an embodiment,”“an illustrative embodiment,” etc., indicate that the embodimentdescribed may include a particular feature, structure, orcharacteristic, but every embodiment may or may not necessarily includethat particular feature, structure, or characteristic. Moreover, suchphrases are not necessarily referring to the same embodiment. Further,when a particular feature, structure, or characteristic is described inconnection with an embodiment, it is submitted that it is within theknowledge of one skilled in the art to effect such feature, structure,or characteristic in connection with other embodiments whether or notexplicitly described. Additionally, it should be appreciated that itemsincluded in a list in the form of “at least one A, B, and C” can mean(A); (B); (C); (A and B); (A and C); (B and C); or (A, B, and C).Similarly, items listed in the form of “at least one of A, B, or C” canmean (A); (B); (C); (A and B); (A and C); (B and C); or (A, B, and C).

In the drawings, some structural or method features, such as thoserepresenting devices, modules, instructions blocks and data elements,may be shown in specific arrangements and/or orderings for ease ofdescription. However, it should be appreciated that such specificarrangements and/or orderings may not be required. Rather, in someembodiments, such features may be arranged in a different manner and/ororder than shown in the illustrative figures. Additionally, theinclusion of a structural or method feature in a particular figure isnot meant to imply that such feature is required in all embodiments and,in some embodiments, may not be included or may be combined with otherfeatures.

In some embodiments, schematic elements used to represent blocks of amethod may be manually performed by a user. In other embodiments,implementation of those schematic elements may be automated using anysuitable form of machine-readable instruction, such as software orfirmware applications, programs, functions, modules, routines,processes, procedures, plug-ins, applets, widgets, code fragments and/orothers, for example, and each such instruction may be implemented usingany suitable programming language, library, application programminginterface (API), and/or other software development tools. For instance,in some embodiments, the schematic elements may be implemented usingJava, C++, and/or other programming languages. Similarly, schematicelements used to represent data or information may be implemented usingany suitable electronic arrangement or structure, such as a register,data store, table, record, array, index, hash, map, tree, list, graph,file (of any file type), folder, directory, database, and/or others, forexample.

Further, in the drawings, where connecting elements, such as solid ordashed lines or arrows, are used to illustrate a connection,relationship, or association between or among two or more otherschematic elements, the absence of any such connection elements is notmeant to imply that no connection, relationship, or association canexist. In other words, some connections, relationships, or associationsbetween elements may not be shown in the drawings so as not to obscurethe disclosure. In addition, for ease of illustration, a singleconnecting element may be used to represent multiple connections,relationships, or associations between elements. For example, where aconnecting element represents a communication of signals, data orinstructions, it should be understood by those skilled in the art thatsuch element may represent one or multiple signal paths (e.g., a bus),as may be needed, to effect the communication.

Referring now to FIG. 1, an illustrative line 100 of land vehiclesincludes a plurality of land vehicles. In the illustrative embodiment,the land vehicle line 100 includes, but is not limited to, atwo-passenger flatbed utility vehicle 110, a 650 cubic foot capacitydelivery vehicle 120, a 1000 cubic foot capacity delivery vehicle 130, asix-passenger flatbed utility vehicle 140, and a 1200 cubic footcapacity delivery vehicle 150. However, in some embodiments, the landvehicle line 100 may include any vehicle having a capacity within aparticular range, such as a range of from 400 cubic feet to 1400 cubicfeet, for example. In keeping with industry terminology, the phrase“cubic foot capacity” may be shortened or abbreviated herein to simply“cube.” It should be appreciated that the phrase “cubic foot capacity”as contemplated herein may refer to a storage volume or storage capacityof a particular land vehicle. In any case, as will be apparent from thediscussion that follows, one or more vehicles of the vehicle line 100may be manufactured using the systems and methods described herein.

In the illustrative embodiment, each of the vehicles included in thevehicle line 100 (i.e., each of the vehicles 110, 120, 130, 140, 150)includes a monocoque or unibody 200 (see FIG. 2) supporting wheels(e.g., wheels 112, 122, 132, 142, 152) to permit movement of theparticular vehicle relative to an underlying surface in use thereof. Asdescribed herein, the monocoque 200 is a single-piece, monolithicstructure unsupported by an internal chassis. The monocoque 200 includesa front cage 210 defining an operator cabin 212 and a rear floor 220positioned rearward of the front cage 210. The monocoque 200illustratively has a composite construction (e.g., the compositestructure 700 shown in FIG. 7) such that each of the front cage 210 andthe rear floor 220 are formed from one or more composite materials, asdescribed in greater detail below.

At least some of the vehicles (e.g., the vehicles 110, 140) of theillustrative line 100 may be embodied as, included in, or otherwiseadapted for use with, electric utility vehicles. Furthermore, at leastsome of the vehicles (e.g., the vehicles 120, 130, 150) of theillustrative line 100 may be embodied as, included in, or otherwiseadapted for use with, electric vehicles having enclosed stowagecompartments. Of course, in other embodiments, it should be appreciatedthat the vehicles of the line 100 may be embodied as, included in, orotherwise adapted for use with, other suitable vehicles.

It should be appreciated each of the vehicles of the illustrative line100 may be employed in a variety of applications. In some embodiments,one or more vehicles of the line 100 may be embodied as, or otherwiseincluded in, a fire and emergency vehicle, a refuse vehicle, a coachvehicle, a recreational vehicle or motorhome, a municipal and/or servicevehicle, an agricultural vehicle, a mining vehicle, a specialty vehicle,an energy vehicle, a defense vehicle, a port service vehicle, aconstruction vehicle, and a transit and/or bus vehicle, just to name afew. Additionally, in some embodiments, one or more vehicles of the line100 may be adapted for use with, or otherwise incorporated into,tractors, front end loaders, scraper systems, cutters and shredders, hayand forage equipment, planting equipment, seeding equipment, sprayersand applicators, tillage equipment, utility vehicles, mowers, dumptrucks, backhoes, track loaders, crawler loaders, dozers, excavators,motor graders, skid steers, tractor loaders, wheel loaders, rakes,aerators, skidders, bunchers, forwarders, harvesters, swing machines,knuckleboom loaders, diesel engines, axles, planetary gear drives, pumpdrives, transmissions, generators, and marine engines, among othersuitable equipment.

In the illustrative embodiment, each of the vehicles of the line 100includes one or more electric motors (not shown) capable of generatingrotational power that may be transmitted to the wheels to drive movementof the vehicle. As such, each of the illustrative vehicles is embodiedas, or otherwise includes, an electric vehicle. Details regarding theelectric motor(s) included in each vehicle and associated powertrainand/or suspension components are described in co-pending U.S. patentapp. Ser. No. XX/XXX,XXX, the contents of which are incorporated hereinby reference in their entirety.

Each of the vehicles of the illustrative line 100 does not include aninternal combustion engine or powerplant, at least in some embodiments.Furthermore, each of the vehicles of the illustrative line 100 does notinclude an engine or powerplant housed by the front cage 210 andpositioned above an underside 214 of the monocoque 200. Instead, asdescribed in co-pending U.S. patent app. Ser. No. XX/XXX,XXX, multipleelectric motors or powerplants are removably coupled to the underside214 of the monocoque 200 of each vehicle of the illustrative line 100.

It should be appreciated that the vehicles of the illustrative vehicleline 100 may each include one or more features that improve theexperience of the driver, the owner, and/or maintenance personnel. Suchfeatures may include, but are not limited to, a low floor, a modularbattery system, air springs and/or air ride features, an independentrear suspension, an independent front suspension, thermal batterymanagement capability, flexible shelving options, desirable driversightlines, LED lighting, telematics/driver feedback, features tofacilitate maintenance, an aerodynamic body, and advanced safetysystems. Further details regarding at least some of these features areprovided herein.

Referring now to FIG. 2, in addition to the front cage 210 and the rearfloor 220, at least in some embodiments, the monocoque 200 includes anintermediate section 230 arranged between the front cage 210 and therear floor 220. The intermediate section 230 may form a portion of afloor section arranged forward of the rear floor 220. As described ingreater detail below with reference to FIG. 8, each of the front cage210, the rear floor 220, and the intermediate section 230 may beassociated with, and formed with, a corresponding mold unit of a modularmold system (e.g., the system 800). Furthermore, as described in greaterdetail below with reference to FIG. 9, the mold units of the modularmold system may be joined together to form a monocoque mold (e.g., themonocoque mold 900) into which composite materials may be introduced toform the monocoque 200.

In the illustrative embodiment, the monocoque 200 combines what wouldtraditionally be formed from one or more separate structures (e.g., oneor more body components and one or more frame components) into asingle-piece, monolithic structure. As such, any vehicle of the presentdisclosure incorporating the monocoque 200 does not include an internalchassis or frame structure that supports separate body components (e.g.,panels, doors, etc.). Due at least in part to consolidation of body andframe components into an integrally-formed structure, the illustrativemonocoque 200 may be associated with, or otherwise facilitate, improvedmanufacturability and/or simplified maintenance compared to otherconfigurations.

Depending on the particular vehicle type and monocoque configuration,one or more dimensions of the intermediate section 230 of the monocoque200 may vary. In one example, the intermediate section 230 may have afirst length associated with, and defined by, a small intermediatesection mold unit (e.g., the mold unit 832 shown in FIG. 8). In thatexample, the first length of the intermediate section 230 may at leastpartially define a stowage compartment of a 650 cubic feet deliveryvehicle (e.g., the vehicle 120). In another example, the intermediatesection 230 may have a second length associated with, and defined by, amedium intermediate section mold unit (e.g., the mold unit 834 shown inFIG. 8). In that example, the second length of the intermediate section230 may at least partially define a stowage compartment of a 1000 cubicfeet delivery vehicle (e.g., the vehicle 130). In yet another example,the intermediate section 230 may have a third length associated with,and defined by, a large intermediate section mold unit (e.g., the moldunit 836 shown in FIG. 8). In that example, the third length of theintermediate section 230 may at least partially define a stowagecompartment of a 1200 cubic feet delivery vehicle (e.g., the vehicle150).

Furthermore, depending on the particular vehicle type and monocoqueconfiguration, the intermediate section 230 of the monocoque 200 may beomitted entirely. In such embodiments, the front cage 210 and the rearfloor 220 may be integrally-formed as a single-piece, monolithicstructure without the intermediate section 230 interposed therebetween.It should be appreciated that the utility vehicles 110 and 140 may eachinclude a monocoque formed without the intermediate section 230, atleast in some embodiments.

Referring now to FIG. 3, a vehicle 300 incorporates the monocoque 200with the intermediate section 230 arranged between the front cage 210and the rear floor 220. Additionally, the vehicle 300 includes a cabhood 302 arranged above the front cage 210 to enclose the operator cabin212 and a stowage compartment 310 arranged rearward of the front cage210 and the cab hood 302. In the illustrative embodiment, the stowagecompartment 310 is at least partially defined by the intermediatesection 230 and the rear floor 220 and has a roof 312 and sidewalls 314.The illustrative vehicle 300 may be similar to any one of the vehicles120, 130, 150 discussed above, at least in some embodiments.

Because the monocoque 200 has a composite construction as indicatedabove, it should be appreciated that any vehicle described herein thatincorporates the monocoque 200 (e.g., any of the vehicles 110, 120, 130,140, 150, 300, 500) incorporates a composite structure (e.g., thestructure 700 shown in FIG. 7). In the case of the vehicle 300, each ofthe intermediate section 230, the roof 312, and the sidewalls 314 isformed from composite materials and has a composite structure, at leastin some embodiments. In those embodiments, each of the intermediatesection 230, the roof 312, and the sidewalls 314 does not includemetallic material.

Referring now to FIG. 4, a prior art delivery vehicle 400 includes astowage compartment 410. The stowage compartment 410 includes a floor412, a pair of sidewalls 414, a ceiling 416, and a refrigeration unit418 at least partially housed by the stowage compartment 410 andconfigured to cool the stowage compartment 410. The rear end of thevehicle 400 includes a landing 404 and a step 406 that leads to thefloor 412 of the stowage compartment 410.

As depicted in FIG. 4, the landing 404 has a landing height 424 aboveground level 402 and the step 406 has a step height 426 above thelanding 404. The floor 412 has a floor height 422 above the ground level402 that includes both the landing height 424 and the step height 426.Typically, the landing height 424 is about 25 inches, the step height426 is about ten inches, and the floor height 422 is about 35 inches.

Referring now to FIG. 5, a delivery vehicle 500 may include a monocoque(e.g., the monocoque 200) described above with reference to FIG. 2.Furthermore, in some embodiments, the vehicle 500 may be similar to oneor more of the vehicles 120, 130, 150 described above. In any case, theillustrative delivery vehicle 500 includes a stowage compartment 510having a floor 512, a pair of sidewalls 514, and a ceiling 516, as wellas a refrigeration unit 518 housed by the stowage compartment 510.Unlike the prior art delivery vehicle 400, however, the vehicle 500lacks a step corresponding to the step 406. As such, the floor 512 has afloor height 522 that substantially corresponds to, and may be equal to,the landing height 424. The floor height 522 may be less than thirtyinches, such as in the range of 22 to 28 inches, for example. A pair ofwheel wells 530 formed within the stowage compartment 510 are offsetfrom one another by a separation distance 532. In certain embodiments,the separation distance 532 may be about 50 inches.

In some cases, the prior art delivery vehicle 400 suffers from one ormore disadvantages not associated with the illustrative vehicle 500. Inone respect, the sidewalls 414 and the ceiling 416 of the prior artvehicle 400 are typically formed of metallic material such as aluminum,for example, which is a poor thermal insulator. As such, the compartment410 may be poorly insulated and have a tendency to adopt the temperatureof the ambient environment relatively quickly. That may be especiallythe case in the summer when radiant heat from the sun supplements theambient hot air to exacerbate the warming of the compartment 410. Incontrast, the sidewalls 514 and the ceiling 516 of the illustrativevehicle 500 are formed of composite materials, which exhibit superiorinsulating characteristics compared to metallic material such asaluminum. Accordingly, the compartment 510 is insulated from the ambientenvironment to a greater degree than the compartment 410. Thatinsulation may be particularly advantageous in cases in which thevehicle 500 is a refrigerated vehicle such as a food delivery vehicle,for instance. It should be appreciated that the insulating properties ofthe compartment 510 may ease the cooling burden on the refrigerationunit 518 and thereby increase performance of the refrigeration unit 518.Additionally, in certain circumstances, increased performance of therefrigeration unit 518 may enable the vehicle 500 to be provided with asmaller refrigeration unit 518 than would typically be required by theprior art vehicle 400.

Another drawback associated with the prior art vehicle 400 is theelevated nature of the floor 412 relative to the ground level 402. Itshould be appreciated that the elevated floor 412 is not merely a designchoice but rather a feature often necessitated to accommodate inclusionof the internal chassis or frame, the powertrain, and associatedcomponents. Put another way, to accommodate the mounting of aconventional internal combustion engine and other powertrain components(e.g., a transmission, transaxle, and/or a differential) to an internalchassis, the floor 412 is elevated above the ground level 402 by thefloor height 422. Consequently, the elevated floor 412 reduces thestorage capacity and/or volume of the stowage compartment 410 andrequires the provision of the step 406. Delivery personnel using thevehicle 400 must therefore step up onto the landing 404 and ascend thestep 406 in order to access the compartment 410.

The illustrative vehicle 500 obviates a number of the aforementioneddisadvantages by eliminating the necessity of the elevated floor 412.Due in part to the provision of the monocoque 200 as a single-piece,monolithically formed structure having a relatively lightweightcomposite construction, and due in part to the absence of powertraincomponents typically provided in other configurations (e.g., a centraldrive shaft beneath the underside 214 of the monocoque 200 that providesa rotational input to a differential), the floor 512 need not beelevated above the ground level like the floor 412. As a result, thevehicle 500 allows increased stowage capacity of the stowage compartment510 to be achieved without raising the ceiling 516. Moreover, because astep similar to the step 406 may be omitted from the vehicle 500, thefloor height 522 corresponds to the landing height 424 of theconventional vehicle 400, and delivery personnel may avoid the effort ofascending both the landing 404 and the step 406 to access the stowagecompartment 510 of the vehicle 500. Notably, it should be appreciatedthat a rear bumper of the vehicle 500 may be slightly lower than thefloor 512 and that delivery personnel may access the compartment 510 byfirst stepping on the rear bumper. In some embodiments, the rear bumpermay have a height of about 20 inches above the ground level, whereas thefloor 512 may have a height of about 25 inches above the ground level.

Referring now to FIG. 6, in the United States, trucks are oftenclassified according to their gross vehicular weight rating (GVWR).Those truck classifications, the associated duty classifications, andthe corresponding GVWRs are illustrated in the table 600. In theillustrative embodiment, one or more of the vehicles 110, 120, 130, 140,150 has a GVWR (i.e., accounting for the weight of the truck when emptyand the payload carrying capacity of the truck when full) of between6,000 pounds and 19,800 pounds. In some embodiments, one or more of thevehicles 110, 120, 130, 140, 150 has a GVWR of between 10,001 pounds and14,000 pounds such that one or more of the vehicles 110, 120, 130, 140,150 is embodied as, or otherwise includes, a Class 3 truck. In oneparticular example, in some embodiments, the 1000 cubic foot capacityvehicle 130 weighs roughly 6,500 pounds when empty and has a 6,000 poundpayload capacity such that the vehicle 130 has a GVWR of about 12,500pounds. Of course, it should be appreciated that in other embodiments,the vehicle line 100 may include one or more vehicles in Class 3, one ormore vehicles in Class 4, and/or one or more vehicles in Class 5.

In some embodiments, the systems and methods described herein may findparticular utility in connection with delivery vehicles in Classes 3through 5. For example, the methods 1000, 1100, 1300 described below maybe utilized to form a monocoque for a delivery vehicle having a GVWRbetween 10,001 pounds and 19,500 pounds. The stowage capacity of such avehicle may be between 450 cubic feet and 1200 cubic feet. In certainembodiments, the stowage compartment (e.g., the compartment 510) of thevehicle may be isolated from the operator cabin (e.g., the operatorcabin 212) of the vehicle.

Referring now to FIG. 7, any vehicle of the present disclosure includesa monocoque having the composite structure 700. In the illustrativeembodiment, the composite structure 700 incorporates one or morerelatively lightweight, low-density materials to impart a relativelylightweight construction to the vehicle. As discussed below, theillustrative composite structure 700 includes one or more of thefollowing: balsa wood, plastic, fiberglass, resin, Kevlar, honeycomb,and carbon fiber. The composite structure 700 does not include, and isnot formed from, metallic material, at least in some embodiments. Inthose embodiments, the monocoque (e.g., the monocoque 200) incorporatingthe composite structure 700 does not include metallic material.

The illustrative composite structure 700 includes a core 702 and a shell704 that at least partially surrounds the core 702. In the illustrativeembodiment, the core 702 is formed from balsa wood and/or one or more ofthe following composite, non-metallic materials: unidirectionalfiberglass, multi-directional fiberglass, Kevlar, carbon fiber, plastic,honeycomb, or other suitable composite, non-metallic materials. Ofcourse, in other embodiments, the core 702 may be formed from othersuitable materials to provide a relatively lightweight construction tothe composite structure 700. The illustrative shell 704 is formed fromfiberglass and resin. However, in other embodiments, the shell 704 maybe formed from other suitable materials. Additionally, in theillustrative embodiment, the composite structure 700 includes a laminatelayer 706 that at least partially covers the shell 704.

It should be appreciated that the composite structure 700 used to formthe monocoque of any vehicle of the present disclosure offers a numberof advantages over multi-piece metallic constructions of conventionalvehicles. In one respect, the single-piece monolithic structure formedwith the composite structure 700 has fewer parts and offers greaterstructural simplicity than vehicle constructions requiring multipleparts. In another respect, the structural simplicity afforded by thecomposite structure 700 may facilitate maintenance and improvestructural efficiency. In yet another respect, due to a lack of metallicmaterial, the composite structure 700 may minimize or eliminate rustand/or corrosion and thereby have a service life that exceeds theservice life of vehicles having conventional constructions. In someinstances, monocoques incorporating composite structures 700 consistentwith the teachings of the present disclosure may have service lives of20 years or more.

Referring now to FIGS. 8 and 9, a modular mold system 800 (see FIG. 8)includes a number of illustrative mold units that may be selected andarranged to form a monocoque system 900 (see FIG. 9). It should beappreciated that when arranged to form the monocoque system 900, theselected mold units of the modular system 800 are utilized to form amonocoque such as the above-described monocoque 200, for example.Furthermore, it should be appreciated that similar reference numerals inthe 800 and 900 series are used to designate corresponding features ofthe modular mold system 800 and the monocoque system 900.

The illustrative mold system 800 includes a front cage mold unit 810, arear floor mold unit 820, and a plurality of intermediate mold units 830having a small intermediate section mold unit 832, a medium intermediatesection mold unit 834, and a large intermediate section mold unit 836.As discussed below, each of the mold units 810, 820, 832, 834, 836 has amold cavity having a size and a shape corresponding to a correspondingfeature of the monocoque system 900 such that subsequent to introductionof the composite materials (e.g., the materials of the compositestructure 700) into the mold cavity, the corresponding feature of themonocoque system 900 will be formed. Accordingly, the front cage moldunit 810 includes a front cage mold cavity 912 that has a size and ashape corresponding to the front cage 910 of the monocoque system 900(and also the front cage 210). The rear floor mold unit 820 includes arear floor mold cavity 922 that has a size and a shape corresponding tothe rear floor 920 of the monocoque system 900 (and also the rear floor220). The intermediate mold units 832, 834, 836 include respectiveintermediate mold cavities 933, 935, 937 each having a size and a shapecorresponding to the respective intermediate section 932, 934, 936 ofthe monocoque system 900 (and also the intermediate section 230).

As evident from FIGS. 8 and 9, each of the intermediate mold units 832,834, 836 is sized for positioning between the front cage mold unit 810and the rear floor mold unit 820 to form the monocoque system 900. Itshould be appreciated that any one of the intermediate mold units 832,834, 836 may be selected and arranged between the front cage mold unit810 and the rear floor mold unit 820 to form the monocoque system 900.Selection of the particular mold unit 832, 834, 836 is based on theconfiguration of the vehicle and the monocoque included therein, asfurther discussed below.

In the illustrative embodiment, the front cage mold cavity 912 of thefront cage mold unit 810 has an opening 914 at a rear end thereof (i.e.,the end closest to one of the intermediate sections 932, 934, 936 asshown in FIG. 9) to establish a fluidic coupling between the cavity 912and another component of the mold system 800. In some embodiments, afluidic coupling may be established between the front cage mold cavity912 and one of the intermediate mold cavities 933, 935, 937 when thefront cage mold unit 810 is arranged contiguously with one of thecorresponding intermediate mold units 832, 834, 836. Additionally, insome embodiments, a fluidic coupling may be established between thefront cage mold cavity 912 and the rear floor mold cavity 922 when thefront cage mold unit 810 is arranged contiguously with the rear floormold unit 820.

In the illustrative embodiment, the rear floor mold cavity 922 of therear floor mold unit 820 has an opening 924 at a front end thereof(i.e., the end closest to one of the intermediate sections 932, 934, 936as shown in FIG. 9) to establish a fluidic coupling between the cavity922 and another component of the mold system 800. Each of theintermediate mold cavities 933, 935, 937 of the intermediate mold units832, 834, 836 has an opening 938 at a front end thereof (i.e., the endclosest to the front cage 910 as shown in FIG. 9) and an opening 940 ata rear end thereof (i.e., the end closest to the rear floor 920 as shownin FIG. 9). When one of the intermediate mold units 832, 834, 836 isarranged contiguously with the front cage mold unit 810, a fluidiccoupling is established between the corresponding intermediate moldcavity 933, 935, 937 and the front cage mold cavity 912 via the openings914, 938. Additionally, when one of the intermediate mold units 832,834, 836 is arranged contiguously with the rear floor mold unit 820, afluidic coupling is established between the corresponding intermediatemold cavity 933, 935, 937 and the rear floor mold cavity 922 via theopenings 924, 940.

It should be appreciated that the front end of each of the illustrativeintermediate mold units 832, 834, 836 is configured for directconnection and attachment to the rear end of the front cage mold unit810. Furthermore, it should be appreciated that the rear end of each ofthe illustrative intermediate mold units 832, 834, 836 is configured fordirect connection and attachment to the front end of the rear floor moldunit 820. Consequently, when any one of the intermediate mold units 832,834, 836 is directly connected with the front cage mold unit 810 and therear floor mold unit 820, the front cage mold cavity 912, thecorresponding intermediate mold cavity 933, 935, 937, and the rear floormold cavity 922 are fluidically coupled to one another in a contiguousarrangement to establish a continuous monocoque mold cavity into whichcomposite materials may be introduced to form the monocoque as asingle-piece, monolithic structure.

It should also be apparent that the rear end of the illustrative frontcage mold unit 810 is configured for direct connection and attachment tothe front end of the rear floor mold unit 820. As a result, when thefront cage mold unit 810 is directly connected to the rear floor moldunit 820, the front cage mold unit 810 and the rear floor mold unit 820are fluidically coupled to one another in a contiguous arrangement toestablish a continuous monocoque mold cavity into which compositematerials may be introduced to form the monocoque as a single-piece,monolithic structure.

In the illustrative embodiment, the small intermediate section mold unit832 has a length L1 as suggested by FIG. 9. The medium intermediatesection mold unit 834 has a length L2 that is greater than the lengthL1, at least in some embodiments. The large intermediate section moldunit 836 has a length L3 that is greater than the length L2 and thelength L1, at least in some embodiments.

In some embodiments, the small intermediate section mold unit 832 may beused to form the intermediate section 932 of the monocoque system 900such that the monocoque at least partially produced using the mold unit832 is included in a vehicle having a storage volume of 650 cubic feet(e.g., the vehicle 120). Additionally, in some embodiments, the mediumintermediate section mold unit 834 may be used to form the intermediatesection 934 of the monocoque system 900 such that the monocoque at leastpartially produced using the mold unit 834 is included in a vehiclehaving a storage volume of 1000 cubic feet (e.g., the vehicle 130). Insome embodiments still, the large intermediate section mold unit 836 maybe used to form the intermediate section 936 of the monocoque system 900such that the monocoque at least partially produced using the mold unit836 is included in a vehicle having a storage volume of 1200 cubic feet(e.g., the vehicle 150).

Referring now to FIG. 10, an illustrative method 1000 of forming amonocoque (e.g., the monocoque 200) using a modular mold system (e.g.,the system 800) is depicted. The method 1000 corresponds to, or isotherwise associated with, performance of the blocks described below inthe illustrative sequence of FIG. 10. It should be appreciated, however,that the method 1000 may be performed in one or more sequences differentfrom the illustrative sequence. Furthermore, it should be appreciatedthat one or more of the blocks described below may be executedcontemporaneously and/or in parallel with one another. In someembodiments, the method 1000 may be performed manually by one or moreoperators. In other embodiments, the method 1000 may be embodied as, orotherwise include, a set of instructions that are performed by anautomated control system.

The illustrative method 1000 begins with block 1002. In block 1002, theoperator(s) or the control system selects a land vehicle type or amonocoque configuration for a particular land vehicle. It should beappreciated that to perform block 1002, the operator(s) or the controlsystem may select any vehicle envisioned by the present disclosure orany monocoque configuration associated with a particular vehiclecontemplated by the present disclosure. From block 1002, the method 1000subsequently proceeds to block 1004.

In block 1004 of the illustrative method 1000, the operator(s) or thecontrol system selects a first mold unit of the modular mold systembased upon the selected vehicle type or monocoque configuration. In theillustrative embodiment, to perform block 1004, the operator(s) or thecontrol system selects the rear floor mold unit 820 of the modularsystem 800 in block 1006. However, in other embodiments, it should beappreciated that block 1004 may be performed by selecting (i) the smallintermediate section mold unit 832 (i.e., in block 1008), (ii) themedium intermediate section mold unit (i.e., in block 1010), or (iii)the large intermediate section mold unit 836 (i.e., in block 1012).Selection of one of the intermediate mold units 832, 834, 836 as thefirst mold unit is described in greater detail below with reference toFIG. 11. In any case, from block 1004, the method 1000 subsequentlyproceeds to block 1014.

In block 1014 of the illustrative method 1000, the operator(s) or thecontrol system couples the selected first mold unit to the front cagemold unit 810 of the modular system 800. It should be appreciated thatto perform block 1014, the selected first mold unit (i.e., the rearfloor mold unit 820) is coupled to the front cage mold unit 810 suchthat the front cage mold cavity 912 is fluidly coupled to the rear floormold cavity 922 to at least partially establish a continuous monocoquemold cavity. Following performance of block 1014, the method 1000proceeds to block 1016.

In block 1016 of the illustrative method 1000, the operator(s) or thecontrol system introduces one or more composite materials (e.g., thecomposite materials included in the composite structure 700) into thecontinuous monocoque mold cavity formed in block 1014. Morespecifically, to perform block 1016, at least in some embodiments, theoperator(s) or the control system performs blocks 1018, 1020, and 1022.In block 1018, the operator(s) or the control system introduces one ormore composite materials into the continuous monocoque mold cavitywithout introducing metallic material into the cavity. In otherembodiments, however, block 1018 may be omitted from the method 1000. Inblock 1020, the operator(s) or the control system places a firstmaterial in the continuous monocoque mold cavity. The first material mayinclude balsa wood and/or plastic, at least in some embodiments. Inblock 1022, the operator(s) or the control system places a secondmaterial different from the first material in the continuous monocoquemold cavity. The second material may include fiberglass and resin, atleast in some embodiments. Following performance of block 1016, themethod 1000 proceeds to block 1024.

In block 1024 of the illustrative method 1000, the operator(s) or thecontrol system cures the one or more composite materials in thecontinuous monocoque mold cavity to form the monocoque. To perform block1024, the operator(s) or the control system may perform blocks 1026,1028, and 1030, at least in some embodiments. In block 1026, theoperator(s) or the control system forms a core (e.g., the core 702)including the first material introduced in block 1016. In block 1028,the operator(s) or the control system forms a shell (e.g., the shell704) including the second material introduced in block 1016 that atleast partially surrounds the core. In block 1030, the operator(s) orthe control system forms a laminate layer (e.g., the layer 706) that atleast partially covers the shell.

Referring now to FIGS. 11 and 12, an illustrative method 1100 of forminga monocoque (e.g., the monocoque 200) using a modular mold system (e.g.,the system 800) is depicted. The method 1100 corresponds to, or isotherwise associated with, performance of the blocks described below inthe illustrative sequence of FIGS. 11 and 12. It should be appreciated,however, that the method 1100 may be performed in one or more sequencesdifferent from the illustrative sequence. Furthermore, it should beappreciated that one or more of the blocks described below may beexecuted contemporaneously and/or in parallel with one another. In someembodiments, the method 1100 may be performed manually by one or moreoperators. In other embodiments, the method 1100 may be embodied as, orotherwise include, a set of instructions that are performed by anautomated control system.

The illustrative method 1100 begins with block 1102. In block 1102, theoperator(s) or the control system selects a land vehicle type or amonocoque configuration for a particular land vehicle. It should beappreciated that to perform block 1102, the operator(s) or the controlsystem may select any vehicle envisioned by the present disclosure orany monocoque configuration associated with a particular vehiclecontemplated by the present disclosure. From block 1102, the method 1100subsequently proceeds to block 1104.

In block 1104 of the illustrative method 1100, the operator(s) or thecontrol system selects a first mold unit of the modular mold systembased upon the selected vehicle type or monocoque configuration. In theillustrative embodiment, to perform block 1104, the operator(s) or thecontrol system performs one of blocks 1106, 1108, and 1110. In block1106, the operator(s) or the control system selects the smallintermediate section mold unit 832. In block 1108, the operator(s) orthe control system selects the medium intermediate section mold unit834. In block 1110, the operator(s) or the control system selects thelarge intermediate section mold unit 836. Following performance of block1104, the method 1100 proceeds to block 1112.

In block 1112 of the illustrative method 1100, the operator(s) or thecontrol system selects a second mold unit of the modular system. In theillustrative embodiment, to perform block 1112, the operator(s) or thecontrol system performs block 1114. In block 1114, the operator(s) orthe control system selects the rear floor mold unit 820 of the modularsystem 800. From block 1112, the method 1100 subsequently proceeds toblock 1116.

In block 1116 of the illustrative method 1100, the operator(s) or thecontrol system couples the selected first mold unit to the front cagemold unit 810 of the modular system 800. It should be appreciated thatto perform block 1116, the selected first mold unit (i.e., one of theintermediate mold units 832, 834, 836) is coupled to the front cage moldunit 810 such that the front cage mold cavity 912 is fluidly coupled tothe corresponding intermediate mold unit cavity (i.e., one of thecavities 933, 935, 937) to at least partially establish a continuousmonocoque mold cavity. Following performance of block 1116, the method1100 proceeds to block 1118.

In block 1118 of the illustrative method 1100, the operator(s) or thecontrol system couples the selected first mold unit (i.e., one of theintermediate mold units 832, 834, 836) to the selected second mold unit(i.e., the rear floor mold unit 820). It should be appreciated that toperform block 1118, one of the intermediate mold units 832, 834, 836 iscoupled to the rear floor mold unit 820 such that the rear floor moldcavity 922 is fluidly coupled to the corresponding intermediate moldunit cavity (i.e., one of the cavities 933, 935, 937) to at leastpartially establish the continuous monocoque mold cavity. Followingperformance of block 1118, the method 1100 proceeds to block 1120.

In block 1120 of the illustrative method 1100, the operator(s) or thecontrol system introduces one or more composite materials (e.g., thecomposite materials included in the composite structure 700) into thecontinuous monocoque mold cavity formed in block 1118. Morespecifically, to perform block 1120, at least in some embodiments, theoperator(s) or the control system performs blocks 1122, 1124, and 1126.In block 1122, the operator(s) or the control system introduces one ormore composite materials into the continuous monocoque mold cavitywithout introducing metallic material into the cavity. In otherembodiments, however, block 1122 may be omitted from the method 1100. Inblock 1124, the operator(s) or the control system places a firstmaterial in the continuous monocoque mold cavity. The first material mayinclude balsa wood and/or plastic, at least in some embodiments. Inblock 1126, the operator(s) or the control system places a secondmaterial different from the first material in the continuous monocoquemold cavity. The second material may include fiberglass and resin, atleast in some embodiments. Following performance of block 1120, themethod 1000 proceeds to block 1202.

In block 1202 of the illustrative method 1100, the operator(s) or thecontrol system cures the one or more composite materials in thecontinuous monocoque mold cavity to form the monocoque. To perform block1202, the operator(s) or the control system may perform blocks 1204,1206 and 1208, at least in some embodiments. In block 1204, theoperator(s) or the control system forms a core (e.g., the core 702)including the first material introduced in block 1120. In block 1206,the operator(s) or the control system forms a shell (e.g., the shell704) including the second material introduced in block 1120 that atleast partially surrounds the core. In block 1208, the operator(s) orthe control system forms a laminate layer (e.g., the layer 706) that atleast partially covers the shell.

Referring now to FIG. 13, an illustrative method 1300 of formingmultiple monocoques of land vehicles using at least one modular moldsystem is depicted. The method 1300 corresponds to, or is otherwiseassociated with, performance of the blocks described below in theillustrative sequence of FIG. 13. It should be appreciated, however,that the method 1300 may be performed in one or more sequences differentfrom the illustrative sequence. Furthermore, it should be appreciatedthat one or more of the blocks described below may be executedcontemporaneously and/or in parallel with one another. In someembodiments, the method 1300 may be performed manually by one or moreoperators. In other embodiments, the method 1300 may be embodied as, orotherwise include, a set of instructions that are performed by anautomated control system.

The illustrative method 1300 begins with block 1302. In block 1302, theoperator(s) or the control system forms a first monocoque of a firstland vehicle. To perform block 1302, the operator(s) or the controlsystem forms the first monocoque of the first land vehicle using atleast one modular system (e.g., the system 800) in block 1304. In someembodiments, the first monocoque of the first land vehicle is formedusing only the front cage mold unit 810 and the rear floor mold unit 820of the modular system 800. In those embodiments, the first monocoque ofthe first land vehicle may be formed by performing the method 1000described above. In other embodiments, the first monocoque of the firstland vehicle is formed using the front cage mold unit 810, the rearfloor mold unit 820, and one of the intermediate mold units 832, 834,836. In those embodiments, the first monocoque of the first land vehiclemay be formed by performing the method 1100 described above. In anycase, following performance of block 1302, the method 1300 proceeds toblock 1306.

In block 1306 of the illustrative method 1300, the operator(s) or thecontrol system forms a second monocoque of a second land vehicle that isdifferent from the first land vehicle. To perform block 1306, theoperator(s) or the control system forms the second monocoque of thesecond land vehicle using at least one modular system (i.e., the system800) in block 1308. In embodiments in which the first monocoque of thefirst land vehicle is formed in block 1302 using only the front cagemold unit 810 and the rear floor mold unit 820 of the modular system 800(i.e., according to the method 1000), the second monocoque of the secondland vehicle is formed using the front cage mold unit 810, the rearfloor mold unit 820, and one of the intermediate mold units 832, 834,836 (i.e., according to the method 1100). In embodiments in which thefirst monocoque of the first land vehicle is formed in block 1302 usingthe front cage mold unit 810, the rear floor mold unit 820, and a firstone of the intermediate mold units 832, 834, 836 (i.e., according to themethod 1100), the second monocoque of the second land vehicle is formedusing the front cage mold unit 810, the rear floor mold unit 820, and asecond one of the intermediate mold units 832, 834, 836 that isdifferent from the first one. Regardless, from block 1306, the method1300 subsequently proceeds to block 1310.

In block 1310 of the illustrative method 1300, the operator(s) or thecontrol system forms a third monocoque of a third land vehicle that isdifferent from the first land vehicle and the second land vehicle. Toperform block 1310, the operator(s) or the control system forms thethird monocoque of the third land vehicle using at least one modularsystem (i.e., the system 800) in block 1310. In embodiments in which (i)the first monocoque of the first land vehicle is formed in block 1302using only the front cage mold unit 810 and the rear floor mold unit 820of the modular system 800 (i.e., according to the method 1000) and (ii)the second monocoque of the second land vehicle is formed in block 1306using the front cage mold unit 810, the rear floor mold unit 820, and afirst one of the intermediate mold units 832, 834, 836 (i.e., accordingto the method 1100), the third monocoque of the third land vehicle isformed using the front cage mold unit 810, the rear floor mold unit 820,and a second one of the intermediate mold units 832, 834, 836 that isdifferent from the first one. In embodiments in which (i) the firstmonocoque of the first land vehicle is formed in block 1302 using thefront cage mold unit 810, the rear floor mold unit 820, and a first oneof the intermediate mold units 832, 834, 836 (i.e., according to themethod 1100) and (ii) the second monocoque of the second land vehicle isformed in block 1306 using the front cage mold unit 810, the rear floormold unit 820, and a second one of the intermediate mold units 832, 834,836 that is different from the first one, the third monocoque of thethird land vehicle is formed using the front cage mold unit 810, therear floor mold unit 820, and a third one of the intermediate mold units832, 834, 836 that is different from the first one and the second one.

While the disclosure has been illustrated and described in detail in theforegoing drawings and description, the same is to be considered asexemplary and not restrictive in character, it being understood thatonly illustrative embodiments thereof have been shown and described andthat all changes and modifications that come within the spirit of thedisclosure are desired to be protected.

What is claimed is:
 1. A land vehicle comprising: a monocoque supportinga plurality of wheels to permit movement of the vehicle relative to anunderlying surface in use of the land vehicle, wherein the monocoque isa single-piece, monolithic structure unsupported by an internal chassis,wherein the monocoque includes a front cage defining an operator cabinand a rear floor positioned rearward of the front cage, and wherein themonocoque has a composite construction such that each of the front cageand the rear floor are formed from one or more composite materials. 2.The land vehicle of claim 1, wherein the monocoque does not includemetallic material, wherein the monocoque includes a core and a shellthat at least partially surrounds the core, wherein the core is formedfrom one or more lightweight, low-density materials, and wherein theshell is formed from resin and fiberglass.
 3. The land vehicle of claim2, wherein the core includes balsa wood.
 4. The land vehicle of claim 3,wherein the core includes one or more of the following: fiberglass,Kevlar, carbon fiber, or plastic.
 5. The land vehicle of claim 4,wherein the monocoque includes a laminate layer that at least partiallycovers the shell.
 6. The land vehicle of claim 1, wherein the monocoqueincludes an intermediate section disposed between the front cage and therear floor, and wherein the vehicle includes a stowage compartment atleast partially defined by the intermediate section and the rear floorthat has a plurality of sidewalls and a ceiling, wherein each of theintermediate section, the plurality of sidewalls, and the ceiling isformed from one or more composite materials, and wherein each of theintermediate section, the plurality of sidewalls, and the ceiling doesnot include metallic material.
 7. The land vehicle of claim 6, whereinthe stowage compartment has a volume of 650 cubic feet, 1000 cubic feet,or 1200 cubic feet.
 8. The land vehicle of claim 6, wherein the vehiclehas a weight limit of between 10,001 pounds and 14,000 pounds.
 9. Theland vehicle of claim 6, further comprising a refrigeration unit atleast partially housed by the stowage compartment that is configured tocool the stowage compartment.
 10. The land vehicle of claim 1, whereinthe vehicle does not include an internal combustion engine.
 11. The landvehicle of claim 10, wherein a height of the rear floor above theunderlying surface is between 22 inches and 28 inches.
 12. A modularsystem for forming a monocoque of a land vehicle, the system comprising:a front cage mold unit including a front cage mold cavity that has asize and a shape corresponding to a front cage of the monocoque definingan operator cabin, the front cage mold unit having an opening at a rearend thereof to establish a fluidic coupling between the front cage moldcavity and another component of the system; a rear floor mold unitincluding a rear floor mold cavity that has a size and a shapecorresponding to a rear floor of the monocoque positioned rearward ofthe front cage, the rear floor mold unit having an opening at a frontend thereof to establish a fluidic coupling between the rear floor moldcavity and another component of the system; and a plurality ofintermediate mold units each sized for positioning between the frontcage mold unit and the rear floor mold unit and each including anintermediate mold cavity that has a size and a shape corresponding to anintermediate section of the monocoque positioned between the front cageand the rear floor, each of the plurality of intermediate mold unitshaving a front opening at a front end thereof to establish a fluidiccoupling between the intermediate mold cavity and the front cage moldcavity and a rear opening at a rear end thereof to establish a fluidiccoupling between the intermediate mold cavity and the rear floor moldcavity.
 13. The system of claim 12, wherein the front end of each of theplurality of intermediate mold units is configured for direct connectionto the rear end of the front cage mold unit.
 14. The system of claim 13,wherein the rear end of each of the plurality of intermediate mold unitsis configured for direct connection to the front end of the rear floormold unit.
 15. The system of claim 14, wherein when any one of theintermediate mold units is directly connected with the front cage moldunit and the rear floor mold unit, the front cage mold cavity, theintermediate mold cavity, and the rear floor mold cavity are fluidicallycoupled to one another in a contiguous arrangement to establish acontinuous monocoque mold cavity into which one or more compositematerials may be introduced to form the monocoque as a single-piece,monolithic structure.
 16. The system of claim 12, wherein the rear endof the front cage mold unit is configured for direct connection to thefront end of the rear floor mold unit.
 17. The system of claim 16,wherein when the front cage mold unit is directly connected to the rearfloor mold unit, the front cage mold unit and the rear floor mold unitare fluidically coupled to one another in a contiguous arrangement toestablish a continuous monocoque mold cavity into which one or morecomposite materials may be introduced to form the monocoque as asingle-piece, monolithic structure.
 18. The system of claim 12, whereinthe plurality of intermediate mold units includes a first intermediatemold unit having a first length, a second intermediate mold unit havinga second length greater than the first length, and a third intermediatemold unit having a third length greater than the second length.
 19. Thesystem of claim 18, wherein the first intermediate mold unit is sized toform an intermediate section of the monocoque included in a vehiclehaving a storage volume of 650 cubic feet, the second intermediate moldunit is sized to form an intermediate section of the monocoque includedin a vehicle having a storage volume of 1000 cubic feet, and the thirdintermediate mold unit is sized to form an intermediate section of themonocoque included in a vehicle having a storage volume of 1200 cubicfeet.
 20. A land vehicle comprising: a monocoque supporting a pluralityof wheels to permit movement of the vehicle relative to an underlyingsurface in use of the land vehicle, wherein the monocoque is asingle-piece, monolithic structure unsupported by an internal chassis,wherein the monocoque includes a front cage defining an operator cabin,a rear floor positioned rearward of the front cage, and an intermediatesection disposed between the front cage and the rear floor, and whereinthe monocoque includes a core formed from balsa wood or plastic and ashell formed from resin and fiberglass that at least partially surroundsthe core; and wherein the monocoque is formed by a modular systemcomprising: a front cage mold unit including a front cage mold cavitythat has a size and a shape corresponding to the front cage of themonocoque, the front cage mold unit having an opening at a rear endthereof to establish a fluidic coupling between the front cage moldcavity and another component of the system; a rear floor mold unitincluding a rear floor mold cavity that has a size and a shapecorresponding to the rear floor of the monocoque, the rear floor moldunit having an opening at a front end thereof to establish a fluidiccoupling between the rear floor mold cavity and another component of thesystem; and an intermediate mold unit sized for positioning between thefront cage mold unit and the rear floor mold unit and including anintermediate mold cavity that has a size and a shape corresponding tothe intermediate section of the monocoque, the intermediate mold unithaving a front opening at a front end thereof to establish a fluidiccoupling between the intermediate mold cavity and the front cage moldcavity and a rear opening at a rear end thereof to establish a fluidiccoupling between the intermediate mold cavity and the rear floor moldcavity.